Part 2

Shafts and Clutches (continued)

Clutch Waved-plate Phase Difference Inspection





1. Place the clutch waved-plate (A) on a surface plate, and set a dial indicator (B) on the waved-plate.
2. Find the bottom (D) of a phase difference of the waved-plate, zero the dial indicator and make a reference mark on the bottom of the waved-plate.
3. Rotate the waved-plate about 72 degrees or 54 degrees apart from the bottom while holding the waved-plate by its circumference, The dial indicator should be at the top (E) of a phase difference. Do not rotate the waved-plate while holding its surface, always rotate it with holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between bottom and top.
Standard: 0.08 - 0.20 mm (0.003 - 0.008 inch)
5. Rotate the waved-plate about 54 degrees or 72 degrees. The dial indicator should be at the bottom of a phase difference (F and H), and zero the dial indicator.
6. Measure the phase difference at the other two tops (G and I) of the waved-plate by following steps 3 thru 5.
7. If the two values of the three measurements are within the standard, the waved-plate is OK. If the two values of the three measurements are out of the standard, replace the waved-plate.

Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston, discs, plates, and end plate for wear and damage, and inspect the 2nd clutch waved-plate phase difference (on 2006 model), if necessary.
2. Install the 1st-hold clutch piston in the 1st clutch piston, and install 1st/1st-hold clutch piston in the 1st/1st-hold clutch drum. Do not install the O-rings on the clutch pistons during inspection.
3. Starting with the 1st-hold clutch plate, alternately install the plates and discs, then install the 1st-hold clutch plate B with the flat side down on the top disc.





4. Measure the 1st-hold clutch plate B-to-top-disc clearance with a feeler gauge (A) while pressing the 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.
5. If the clearance is out of standard, replace the 1st hold clutch plates and discs as a set, and recheck.
6. Install the disc spring on the 1st-hold clutch plate B with the large end down. Starting with the clutch plate, alternately install the plates and discs in the 1st clutch drum, then install the clutch-end-plate with the flat side down on the top disc. Install the snap ring to secure the clutch-end-plate.





7. Install the clutch pistons in the 2nd, 3rd, 4th, and 5th clutch drums. Do not install the O-rings on the clutch pistons during inspection.
8. Starting with the clutch plate, alternately install the clutch plates and discs in the clutch drums, then install the clutch-end-plate with the flat side down on the top disc. Install the snap ring to secure the clutch-end-plate.





9. Set a dial indicator (A) on the clutch-end-plate (B).
10. Zero the dial indicator with the clutch-end-plate lifted up to the snap ring (C).





11. Release the clutch-end-plate to lower the clutch-end-plate, then put the special tool on the end-plate (A).
12. Press the special tool down with 39 N (4 kgf, 9 lbs.) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch-end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
13. Only for the 2nd clutch on the 2006-2007 models:
Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbs.) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch-end-plate and top disc (E). Take measurements in at least three places, and use the average as the actual clearance.
Clutch-End-Plate-to-Top Disc Clearance
Service Limit:
2003-2005 Models
1st clutch: 1.1 - 1.3 mm (0.043 - 0.051 inch)
2nd clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)
3rd clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)
4th clutch: 0.55 - 0.75 mm (0.022 - 0.030 inch)
5th clutch: 0.55 - 0.75 mm (0.022 - 0.030 inch)
2006-2007 Models
1st clutch: 1.1 - 1.3 mm (0.043 - 0.051 inch)
2nd clutch: 0.85 - 1.05 mm (0.033 - 0.041 inch)
3rd clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)
4th clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)
5th clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)

1ST CLUTCH END PLATES:

2ND CLUTCH END PLATES:

3RD CLUTCH END PLATES:

4TH AND 5TH CLUTCH END PLATES:

14. If the clearance is out of the service limit, select a new clutch-end-plate from the following table.
15. Install the new clutch-end-plate, and recheck the clearance. If the thickest clutch-end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.

Clutch Reassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100 or 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.





2. Install the new O-rings (A) on the clutch piston.





3. Install the clutch pistons in the clutch drums while applying pressure and rotating to ensure proper seating. Do not pinch the O-ring.





4. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the spring retainer.





5. Install the special tools.





6. Set the special tool (A) over the spring retainer (B), and make sure the special tool is adjusted to have full contact with the Spring retainer on the 1st, 4th, and 5th clutches.





7. Set the special tool (A) on the spring retainer (B) of the 2nd clutch so the tool works on the clutch return spring (C).





8. If either end of the special tool is set over an area of the spring retainer that is unsupported by the return spring, the retainer may be damaged.





9. Set the special tool (A) on the spring retainer (B) of the 3rd clutch so the special tool works on the clutch return spring (C).





10. If either end of the special tool is not set over the clutch return spring end (A), the retainer may be damaged,





11. Compress the return spring until the snap ring can be installed.





12. Install the snap ring with the snap ring pliers.
13. Remove the special tools.





14. Install the waved spring in the 3rd clutch (2003 model) and 4th clutch (2003-2004 models).








15. Install the disc spring in the 1st clutch, 5th clutch, 3rd clutch (2004-2007 models), and 4th clutch (2005-2007 models).
16. Make sure the inside of the clutch drum is free of dirt and other foreign particles.





17. For 1st, 3rd, 4th, and 5th clutches:
Starting with the clutch plate, alternately install the clutch plates and discs in the clutch drums, then install the clutch-end-plate with the flat side down on the top disc.
18. For 2nd clutch:
Starting with the 2nd clutch plate, alternately install the clutch flat-plates (4) and discs (4) in the clutch drum, and alternately install the clutch waved plates (2) and discs (2), then install the clutch-end plate with the flat side down on the top disc.





19. Install the snap ring with a screwdriver to secure the clutch-end-plate.
20. Check that the clutch piston moves by applying air pressure into fluid passage.